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E 2008 Lennox Industries Inc.
Dallas, Texas 75379-9900
This manual provides operation instructions for model
RGEN30 residential generator sets.
Refer to the engine operation manual for generator set engine scheduled maintenance information.
This generator set is approved for use in stationary standby applications in locations served by a reliable utility power source.
Have a Lennox dealer who is approved to sell and install Lennox generator sets
(hereinafter referred to as a Lennox dealer) install the generator set.
Refer to XP-6341, Installation
Instructions, for installation information. See the List of
Related Literature in the Introduction section.
Information in this publication represents data available at the time of print. The manufacturer reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section. Keep this manual with the equipment for future reference.
The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals.
Obtain service from a Lennox dealer or service technician to keep equipment in top condition.
OPERATION
MANUAL
RGEN30
RESIDENTIAL GENERATOR SET
XP-6344 6/10b
Table of Contents
Product Identification Information . . . . . . . . . . . . . . .
Safety Precautions and Instructions
Introduction
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Service Views
Section 2 Operation
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Operating Area . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Exercising Generator Set
2.4
Controller Operation
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . .
3.1
General Maintenance . . . . . . . . . . . . . . . . . . . . . . .
3.2
Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5
Exhaust System
3.6
Cooling System
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9
Belt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . .
4.1
Introduction
4.2
Fault Codes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
Generator Set Troubleshooting . . . . . . . . . . . . . .
4.5
Controller Troubleshooting . . . . . . . . . . . . . . . . . .
24
26
26
26
19
19
21
21
23
26
27
28
15
16
17
18
10
10
11
11
15
2
8
10
3
7
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Shipping and Packing List
1 -- Generator Set
Check equipment for shipping damage. If you find any damage, immediately contact the last carrier.
506089-01
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.
Record field-installed kit numbers after installing the kits.
Generator Set Identification Numbers
Record the product identification numbers from the generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Controller Identification
Record the controller description from the generator set operation manual, spec sheet, or sales invoice.
Controller Description
Engine Identification
Record the product identification information from the engine nameplate.
Manufacturer
Model Designation
Serial Number
2 XP-6344 6/10
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.
Read and follow all safety precautions and instructions.
SAVE
THESE INSTRUCTIONS.
This manual has several types of safety precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a hazard that will cause severe personal injury, death, substantial property damage.
or
WARNING
Warning indicates the presence of a hazard that can cause severe personal injury, death, substantial property damage.
or
CAUTION
Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.
The decals are shown throughout this publication to improve operator recognition.
Replace missing or damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
WARNING
XP-6344 6/10
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.
Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.
Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup. Battery acid can cause severe injury or death.
Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.
Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.
Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded
Safety Precautions and Instructions 3
metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.
Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits.
Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Disconnect the battery before generator set installation or maintenance.
Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Engine Backfire/Flash
Fire
Fire.
carburetor.
WARNING
Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the fuel system. A flash fire can cause severe injury or death.
Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
Catch fuels in an approved container when removing the fuel line or
Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.
Combustible materials. A fire can cause severe injury or death.
Generator set engine fuels and fuel vapors are flammable and explosive.
Handle these materials carefully to minimize the risk of fire or explosion.
Equip the compartment or nearby area with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as recommended by the local fire code or an authorized agency.
Train all personnel on fire extinguisher operation and fire prevention procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in joints and muscles
D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.
Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
Carbon monoxide detectors.
Carbon monoxide can cause severe nausea, fainting, or death.
Install carbon monoxide detectors on each level of the building.
Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer’s instructions.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
The fuel system.
Explosive fuel vapors can cause severe injury or death.
Vaporized fuels are highly explosive.
Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.
Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines.
Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Explosive fuel vapors can cause severe injury or death.
Take additional precautions when using the following fuels:
4 Safety Precautions and Instructions XP-6344 6/10
Propane (LP)—Adequate ventilation is mandatory.
Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions.
Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer’s instructions.
Gas fuel leaks.
Explosive fuel vapors can cause severe injury or death.
Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
Hazardous Noise
CAUTION
Hazardous Voltage/
Moving Parts
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than
105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.
Hazardous voltage.
Backfeed to the utility system can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.
CAUTION
Welding the generator set.
Can cause severe electrical equipment damage.
Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads.
High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.
Welding on the generator set. Can cause severe electrical equipment damage.
Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module
(ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection close to the weld location.
Installing the battery charger.
Hazardous voltage can cause severe injury or death.
An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.
XP-6344 6/10 Safety Precautions and Instructions 5
Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
Have a qualified electrician install the battery(ies).
Short circuits.
Hazardous voltage/current can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Do not contact electrical connections with tools or jewelry while making adjustments or repairs.
Remove all jewelry before servicing the equipment.
Engine block heater.
Hazardous voltage can cause severe injury or death. The engine block heater can cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections.
Electrical backfeed to the utility.
Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power.
Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.
WARNING
Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.
Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.
Heavy Equipment
WARNING
Unbalanced weight.
Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Lift the generator set using lifting bars inserted through the lifting holes on the skid.
Hot Parts
WARNING
Airborne particles.
Can cause severe injury or blindness.
Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the alternator. Hot parts can cause severe injury or death.
Avoid touching the alternator field or exciter armature.
When shorted, the alternator field and exciter armature become hot enough to cause severe burns.
Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.
The engine and exhaust system components become extremely hot during operation.
Notice
NOTICE
Canadian installations only.
For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD) damages electronic circuit boards.
Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about
1 megohm), not a direct short, to ground.
6 Safety Precautions and Instructions XP-6344 6/10
Introduction
List of Related Literature
Figure 1 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.
Literature Type
Installation Manual, RGEN30
Parts Catalog*
Service Manual (Engine)
[
Service Manual (Engine) w
Service Manual (Generator Set)
Part Number
XP-6341
XP-6319
TP-6362
TP-6724
XP-6198
Instruction Sheet, Oil Makeup Kit TT-1521
* One Parts Catalog combines generator and engine information.
[ Generator set serial numbers before 2272938 w Generator set serial numbers after 2272938
Figure 1 Generator Set Literature
XP-6344 6/10 Introduction 7
21
1 2 3
Section 1 Service Views
4 5
6
7
8
20
19
18
17
16
29
15 14 13 12
Service-Side View
11 10 9
22
23
24
25
30
Oil Makeup Kit
31
28 27 26
Nonservice-Side View
1. Air cleaner
2. Oil check
3. Oil fill (on valve cover)
4. Fuel/air mixer
5. Pressure cap (engine coolant fill)
6. Coolant overflow tube
7. Radiator
8. Belt guard
9. LOP switch location
10. Coolant overflow bottle
11. Secondary fuel regulator
12. Positive (+) battery connection point
13. Oil drain valve
14. Fuel solenoid valves (two required for UL 2200)
15. Fuel inlet
16. AC circuit breaker panel
GM32850D-R
17. Fuses
18. Generator set master switch
19. Controller
20. Runtime hour display
21. Engine control module (ECM)
22. Spark plugs
23. Nameplate
24. Remote customer interface connector
25. Customer load lead access
26. Lube oil filter
27. Negative (--) battery connection point
28. Coolant drain
29. Cooling air inlet
30. Oil makeup assembly with sight gauge
31. Oil reservoir
Figure 1-1 Service Views, shown without enclosure (generator set serial numbers before 2272938)
8 Section 1 Service Views XP-6344 6/10
1
2 3
17
16
15
14
13
4
5
6
30
12 11 10 9
18 19 20 21
8 7
Oil Makeup Kit
29
22
23
ADV-7962
28 27 26 25 24
1. Air cleaner
2. ECM and EPR (electronic fuel pressure regulator)
3. Pressure cap (engine coolant fill)
4. Coolant overflow tube
5. Radiator
6. Belt guard
7. Coolant overflow bottle
8. LOP switch location
9. Positive (+) battery connection point
10. Oil drain valve
11. Fuel solenoid valves (two required for UL 2200)
12. Fuel inlet
13. AC circuit breaker panel
14. Generator set fuses
15. Generator set master switch
16. Controller
17. Nameplate
18. Spark plugs
19. Oil fill (on valve cover)
20. Engine fuses
21. Oil check (dipstick)
22. Remote customer interface connector
23. Customer load lead access
24. Battery cables
25. Battery location (battery not shown)
26. Lube oil filter
27. Negative (--) battery connection point
28. Coolant drain
29. Cooling air inlet
30. Oil makeup assembly with sight gauge
31. Oil reservoir
Figure 1-2 Service Views, shown without enclosure (serial numbers after 2272938)
31
XP-6344 6/10 Section 1 Service Views 9
Section 2 Operation
2.1 Operating Area
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases.
Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in joints and muscles
D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning.
Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
Keep the generator set area clear. Maintain at least
1.5 m (5 ft.) of clearance on all sides of the generator set. Verify that there are no windows, air vents, or other openings in the building within 1.5 m (5 ft.) of the generator set exhaust outlet in any direction.
Notice
Do not locate patios, decks, play areas, or animal shelters near the generator set. Keep items such as lawn furniture, toys, sports equipment, and all combustible materials away from the generator set exhaust outlet. Remind family members, children, and visitors to use caution near the generator set.
Generator sets connected to automatic transfer switches start automatically during exercise periods and power outages.
Some generator set components become hot when the generator set is running and remain hot for a time after the generator set shuts down.
10 Section 2 Operation
2.2 Prestart Checklist
To ensure continued satisfactory operation perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.
Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.
Air Inlets. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.
Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.
Coolant Level. Check the coolant level according to the cooling system maintenance information.
Note: Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system before energizing the block heater.
Drive Belt(s). Check the belt condition of the water pump and battery charging alternator belt(s).
Exhaust System.
Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.
Inspect the exhaust system components for cracks and corrosion (exhaust manifold, exhaust pipe, exhaust clamps, and silencer).
D
Check for corroded or broken metal parts and replace them as needed.
D
Check that there are no combustible materials near the exhaust outlet.
D
Check that the exhaust outlet is unobstructed.
Carbon Monoxide Detectors.
Check for the installation and operation of carbon monoxide (CO) detectors on each level of any building near the generator set.
Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.
XP-6344 6/10
2.3 Exercising Generator Set
Operate the generator set once each week for
20 minutes.
The operator should perform all of the prestart checks before starting the exercise procedure.
Start the generator set according to the starting procedure in the controller section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks.
2.4 Controller Operation
Figure 2-1 illustrates the user interface on the controller.
Note: Have setup and adjustments of the controller performed only by a Lennox dealer. The setup and adjustments are password protected.
The buttons on the controller keypad are used only for system configuration and adjustment. The controller is factory-set and should not require configuration or adjustment under normal operating conditions. If the generator set is reconnected to a different voltage and/ or frequency, refer to a Lennox dealer for system configuration and adjustment instructions.
4
1 2
2.4.1
Controls and Indicators
Figure 2-2 describes the controls and indicators located on the controller. The LED display indicates generator set status as shown in Figure 2-2. The display is active when the master switch is in the RUN or AUTO position and remains active until the generator set master switch is moved to the OFF/RESET position or the power to the controller is removed.
Depending on the controller configuration, the LED display may turn off after a period of inactivity when the master switch is in AUTO.
See
Section 2.4.6.
3
1. LED display
2. Up and down arrow buttons
(use for setup and adjustment only)
3. Generator set master switch
4. Select button (use for setup and adjustment only)
Figure 2-1 Controller
GM28707A-C
Control or Indicator Item
LED display Runtime hours
Description
Displays total generator set runtime hours.
Crank indication Displays CC_1, CC_2, or CC_3 to indicate the first, second or third attempt to start the engine. The last digit flashes during the crank cycle rest periods.
Fault codes Flashes a 2- or 3-letter fault code to indicate various fault conditions. See
Section 2.4.4.
See the generator set installation manual.
Keypad
Generator set master switch (RUN-OFF/
RESET-AUTO)
Software version
Select and arrow buttons
Three-position switch
The keypad is used for controller setup and adjustment only. Have setup and adjustments performed only by a Lennox dealer. The setup and adjustment functions are password-protected.
Switch functions as the generator set operation and controller reset switch.
Figure 2-2 Controls and Indicators
XP-6344 6/10 Section 2 Operation 11
2.4.2
Local Operation
Starting. Move the generator set master switch to the
RUN position.
The controller attempts to start the generator set three times. If the generator set does not start in three attempts, the system shuts down on an overcrank fault.
The crank cycle time is preprogrammed and not adjustable.
Stopping. Run the generator set with no load for at least 2 minutes to allow the engine to cool down. Move the generator set master switch to the OFF/RESET position. The engine stops.
2.4.3
Automatic Operation
The generator set can be connected to an automatic transfer switch (ATS), remote start/stop switch or remote digital gauge. Move the generator set master switch to the AUTO position to allow starting and stopping by one of these devices.
Refer to the instructions provided with the ATS, remote start/stop switch or remote digital gauge for operation instructions.
Note: Have a Lennox dealer install and connect the
ATS, remote start/stop switch, or remote digital gauge.
Automatic Starting. The generator set crank cycle starts when the remote switch or engine start contacts on the ATS close. The controller attempts to start the generator set three times. If the generator set does not start in three attempts, the system shuts down on an overcrank fault.
The crank cycle time is preprogrammed and not adjustable.
Automatic Stopping. With the generator set master switch in the AUTO position, the generator set stops when the remote start/stop switch contacts or engine start contacts on the ATS open.
2.4.4
Fault Warnings and Shutdowns
Warnings. The controller displays a fault code but the generator set does not shut down under the high battery voltage (HB) and low battery voltage (LB) warning conditions shown in Figure 2-3. The controller resets automatically after a battery voltage fault condition is corrected.
Shutdowns.
The generator set shuts down automatically under the conditions listed in Figure 2-4 and the controller displays a fault code. Correct the fault condition and then reset the controller before restarting the generator set.
See Section 2.4.5 to reset the controller after a fault shutdown.
Shutdown switches on the generator set automatically reset when the problem is corrected. For example, the high engine temperature switch on the generator set engine automatically resets when the generator set cools. However, the fault on the controller does not clear until the operator resets the controller.
LOP Shutdown. The oil pressure switch shuts down the generator set if the oil pressure drops below a preset level, providing some protection from major engine damage due to insufficient oil pressure. However, the low oil pressure switch is not a low oil level indicator.
Check the oil regularly as described in the service schedule and add oil as required to keep the oil level at or near the full mark on the dipstick or optional gauge.
Code Fault
HB High battery voltage warning
LB Low battery voltage warning
Description
Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running.
This fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.
Check
Check the battery rating and condition.
Fault code is displayed if the engine starting battery voltage falls below
9.5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 10 seconds when the engine is not running. This fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.
Check the battery rating and condition.
Charge or replace the battery.
Figure 2-3 Fault Warning Codes
12 Section 2 Operation XP-6344 6/10
Code
AF
HE
Fault
Auxiliary fault input shutdown
High engine temperature shutdown
Description
Input from a customer-supplied switch that closes when the fault is active. The generator set shuts down 0.3 seconds after the fault is detected and will not start when the fault is active (input is grounded).
This protection becomes active 3 seconds after crank disconnect.
Check
Check the cause of the auxiliary fault.
Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than
5 seconds. This protective becomes active after the engine reaches the crank disconnect speed.
Not used.
Check for blocked air inlets and exhaust outlets.
— LCL Low coolant level
LOC Loss of coolant Not used.
LOP Low oil pressure shutdown
Shutdown occurs if a low oil pressure condition exists for more than 5 seconds. This protective becomes active 30 seconds after the engine has reached crank disconnect speed (30 second inhibit).
OC Overcrank shutdown
Shutdown occurs after 3 unsuccessful starting attempts. The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest.
The generator set also shuts down if no engine rotation is sensed during cranking. Shuts down
1 second after the fault is detected.
—
Check for leaks in the lubrication system.
Check the oil level and add oil if the level is low.
Check the fuel supply, spark plug, and battery.
Check for loose connections.
Contact a Lennox dealer for service if problem continues.
OF
OS
OU
UF
UU
SCF0
Overfrequency shutdown
Overspeed shutdown
Overvoltage shutdown
Underfrequency shutdown
Undervoltage shutdown
Software
Communication
Fault 0
Shutdown occurs when the governed frequency exceeds 110% of the system’s frequency setpoint for more than 5 seconds. This protective becomes active 10 seconds after engine start (10 second inhibit).
Shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than
0.3 seconds.
Contact a Lennox dealer for service if problem continues.
Contact a Lennox dealer for service if problem continues.
Shutdown occurs if the voltage exceeds 120% of the system nominal voltage for more than 2 seconds.
Contact a Lennox dealer for service if problem continues.
Shutdown occurs when the governed frequency falls below 90% of the nominal system frequency for more than 5 seconds or below 59 Hz for more than
60 seconds. This protective becomes active
10 seconds after engine start. (10 second inhibit).
Shutdown occurs if the voltage falls below 80% of the nominal system voltage for more than
10 seconds.
Indicates a software or communication problem within the controller
.
Reduce the load and restart the generator set.
Contact a Lennox dealer for service if problem continues.
Reduce the load and restart the generator set.
Contact a Lennox dealer for service if problem continues.
Replace the controller.
Figure 2-4 Fault Shutdown Codes
XP-6344 6/10 Section 2 Operation 13
2.4.5
Resetting Controller After a Fault
Shutdown
Always identify and correct the cause of a fault shutdown before resetting the controller.
Use the following procedure to reset the generator set controller after a fault shutdown.
1. Move the generator set master switch to the OFF/
RESET position.
2. Disconnect the generator set from the load using the line circuit breaker or ATS. See the safety precautions at the beginning of this manual before proceeding.
3. Identify and correct the cause of the fault shutdown. Refer to Section 4, Troubleshooting.
4. Start the generator set by moving the generator set master switch to RUN. Test operate the generator set to verify that the cause of the shutdown has been corrected.
5. Stop the generator set by moving the generator set master switch to the OFF/RESET position.
6. Reconnect the generator set to the load using the line circuit breaker or ATS.
7. If the generator set is connected to a transfer switch, remote start/stop switch, or remote digital gauge, move the generator set master switch to the
AUTO position.
Note: Opening and closing the remote start/stop contact also resets the controller. Always identify and correct the cause of the fault shutdown before restarting the generator set.
2.4.6
Controller Power Down
The controller is powered by the generator set’s engine starting battery.
When the generator set master switch is in the AUTO position, the controller may power down after a period of inactivity. The controller’s communication parameter
(Cn) setting determines the power down mode. See the installation Instructions, XP-6341, for controller configuration information.
48-hour power down (default setting).
If the controller communication parameter is set to Cn00, the controller automatically powers down after 48 hours of inactivity. A remote start signal (from a transfer switch or a remote start/stop switch connected to P21 connector, leads 3 and 4) or moving the generator set master switch to the RUN position turns the controller back on.
Continuous power mode.
If the controller communication parameter is set to Cn01, the controller will not power down. The controller remains powered at all times to maintain CANbus communication and to allow remote start commands from a remote CAN gauge. A battery charger is recommended to maintain the engine starting battery.
Note: The controller draws 250 mA when the master switch is in the AUTO position and the unit is configured for CAN communication.
1-hour power down.
Setting the communications parameter to Cn06 will cause the controller to power down after 1 hour of inactivity. In this mode, a remote digital gauge using CAN communication will not be able to activate the controller after power down. A remote start signal (from a transfer switch or a remote start/stop switch connected to P21 connector, leads 3 and 4) or moving the generator set master switch to the RUN position turns the controller back on.
Controller application code version 1.21 or higher is required for the 1-hour power down option.
14 Section 2 Operation XP-6344 6/10
Section 3 Scheduled Maintenance
3.1 General Maintenance
WARNING
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the exhaust system.
Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.
Replace guards, screens, and covers before operating the generator set.
The engine and generator set may use both American
Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.
See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have a Lennox dealer perform generator set service.
Engine Service. Perform generator set engine service at the intervals specified by the engine operation manual.
Generator Set Service. Perform generator set service at the intervals specified by the generator set operation manual.
If the generator set operates under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator. With the generator set running, direct the stream of air in through the cooling slots at the alternator end.
Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the runtime hours shown on the controller to determine when to schedule routine maintenance.
Service generator sets that are subject to extreme weather or dusty or dirty conditions more frequently.
XP-6344 6/10 Section 3 Scheduled Maintenance 15
3.2 Service Schedule
Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set.
Perform Service at Intervals Indicated (X)
Fuel System
Check the fuel level and fill as necessary (LP).
Check the solenoid valve operation.*
Check flexible fuel lines and connections. Replace as necessary.*
Check the fuel piping.*
Lubrication System
Check the oil level and add oil as necessary.
Change the oil.
Replace the oil filter.
Intake/Exhaust System
Inspect and clean the air cleaner element.
Replace the air cleaner element.
Check and clear the exhaust outlet area.
Inspect the exhaust system components.*
Check the installation and operation of CO detectors.
Check the exhaust gas condition during operation.
Cooling System
Check the coolant level and fill as necessary.
Inspect the radiator and hoses.
Check the belt tension and condition.*
Check the coolant protection and tighten the hose clamps.*
Flush the cooling system.*
Ignition System
Clean and regap the spark plugs.
Replace the spark plugs.
Electrical System
Keep the battery charged and in good condition.
]
Check and tighten electrical connections.*
Clean the battery cables as required.
]
Engine And Mounting
Check for fuel, coolant, and oil leakage.*
[
Retighten all nuts and bolts as required.
Check for visible wear or damage.
Remote Control System
Check the remote control operation.
Generator Set
Exercise the generator set.
Check and clean the interior of the enclosure.
Clean collector ring and inspect brushes.*
Reference
Section
Before
Starting
Weekly
3.3.2
3.3.5
3.3.5
3.4
3.4
3.5
3.5
3.5
3.5
3.6.1
3.6.1
3.9
3.6.1
3.6.4
3.8
3.8
3.7
2.3
3.1
X
X (24 hr.)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
100 Hr.
(3 Mo.)
X
X (150 hr.)
X (150 hr.)
X
X
300 Hr.
(6 Mo.)
400 Hr.
(Yearly)
X
X
X
X
X (800 hr.)
X (800 hr.)
X
X
X
(1000 hr.)
* Contact a Lennox dealer for service.
[ Read WARNING found at the beginning of manual regarding moving parts.
] Consult battery manufacturer’s instructions.
16 Section 3 Scheduled Maintenance XP-6344 6/10
3.3 Lubrication System
3.3.1
Oil Specifications
Use oil that displays the American Petroleum Institute
(API) Starburst certification mark FOR GASOLINE
ENGINES on the container. Do not use oils that are specifically formulated for diesel engines. CC or CD classification oils, even when labeled Heavy Duty or For
Natural Gas Engines are not acceptable.
Multi-viscosity oils are recommended.
Figure 3-1 shows the recommended Society of Automotive
Engineers (SAE) viscosity designation for a given operating temperature.
Ambient Temperature
--18
_C (0_F) or above
Below --18
_C (0_F)
Figure 3-1 Engine Oil Selection
SAE Viscosity Grade
10W-30
5W-30
Do not mix different oil brands. Incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection.
3.3.2
Oil Check
Check the oil level in the crankcase every 24 hours of operation or before each startup. Do not check the oil level while operating the unit. Stop the generator set and keep the generator set level to get an accurate reading. To check the oil level, remove the dipstick and wipe the end clean, reinsert and remove. Maintain the oil level between the Full and Add marks on the dipstick, as shown in Figure 3-2. See Section 1, Service Views for the dipstick location.
Note: Do not operate the set if the oil level is below the
Add mark or above the Full mark on the dipstick.
1
2
1. Full mark
2. Add mark
Figure 3-2 Oil Level Check
TP-5586-3
3.3.3
Oil Makeup Kit
On generator sets equipped with the oil makeup kit, check the oil level in the oil reservoir and at the sight gauge. Refer to the instructions provided with the oil makeup kit for more information.
3.3.4
Oil Additions
Adding some oil between oil changes is normal. The amount varies with generator set usage. Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device. See Section 1, Service
Views, for the oil check and oil fill locations.
3.3.5
Oil and Filter Change
Change the oil according to the service schedule or before generator set storage.
Change the oil more frequently if the generator set operates under dirty, dusty conditions. Change the oil while the engine is still warm. See Section 1, Service Views, for oil fill, oil check, and oil filter locations.
Oil Change Procedure
Whenever possible, drain the oil while it is still warm.
1. Drain the oil.
a. Place the generator set master switch in the
OFF position.
b. Disconnect the power to the battery charger, if equipped.
c. Disconnect the generator set engine starting battery, negative (--) lead first.
d. Remove the housing side panel.
e. Place an oil collection container below the oil drain and remove the oil drain plug.
f. Open the oil drain valve on the engine.
g. Allow time for the engine oil to drain completely.
h. Close the oil drain valve.
i. Replace the oil drain plug. Replace the cap on the oil drain hose. Replace the oil drain hose in its retaining clip.
2. Replace the oil filter.
a. Remove the oil filter by rotating it counterclockwise with an oil filter wrench.
b. Clean the contact surface of the oil filter adapter.
XP-6344 6/10 Section 3 Scheduled Maintenance 17
c. Apply a light coat of clean oil to the rubber seal of the new oil filter.
d. Install the new oil filter following the instructions provided with the filter.
Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner.
3. Fill with oil. See Figure 3-1 for oil selection and
Figure 3-3 for oil capacity.
Model
RGEN30
RGEN30 with oil makeup kit
Figure 3-3 Oil Capacity
4. Check for leaks.
Oil Capacity, L (qt.)
3.5 (3.7)
5.4 (5.7) a. Check that the generator set master switch is in the OFF position.
b. Reconnect the generator set engine starting battery, negative (--) lead last.
c. Reconnect the power to the battery charger.
d. Start the generator set and check for leaks around the oil filter.
e. Stop the generator set and tighten the oil filter to stop any leaks.
f. Reinstall the housing side panel.
5. Stop the generator set. Check the oil level. Add oil, as necessary, to bring the level up to the Full mark.
Note: Too high an oil level causes high oil consumption and engine carbonizing. Too low a level damages the engine.
3.4 Air Cleaner
At the interval specified in the service schedule, inspect, clean, or replace the air cleaner element. Clean the element more frequently in dirty, dusty conditions.
Check the element for accumulated oil or dirt that could cause poor performance.
Replace a damaged air cleaner element.
Follow the procedure described below.
Air Cleaner Service Procedure
A dry-type air cleaner silences and filters the intake air.
The air intake silencer assembly connects to the intake manifold via a flexible hose. Refer to Figure 3-4 during this procedure.
1
2 3 4
GM21379
5
6
1. Cover
2. Spring clip(s)
3. Housing
4. Pressure tap (1/8-27 NPT)
Figure 3-4 Air Cleaner
5. Primary element
6. Dust ejector
1. Release the spring clips to open the housing and remove the air silencer element.
2. Tap the element lightly against a flat surface to dislodge loose surface dirt.
Do not clean the element in any liquid or use compressed air as these will damage the filter element.
3. Examine the element and housing for damage.
Replace the element or housing if necessary.
4. Wipe the cover and housing with a clean rag to remove dirt. Make sure the sealing surfaces fit correctly and reattach the spring clips.
18 Section 3 Scheduled Maintenance XP-6344 6/10
3.5 Exhaust System
WARNING
D
Check that all covers and doors are undamaged, in place, and locked.
D
Check for the installation and operation of carbon monoxide (CO) detectors on each level of any building near the generator set.
3.6 Cooling System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Carbon monoxide detectors.
Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of the building. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer’s instructions.
At the interval specified in the service schedule, inspect the exhaust system components (exhaust manifold, exhaust outlet, exhaust line, exhaust clamps, and muffler) for cracks, leaks, and corrosion.
Exhaust System Inspection Points
D
Check for corroded or broken metal parts and replace them as needed.
D
Check that the exhaust outlet is unobstructed.
D
Check the exhaust gas color. If the exhaust is blue or black, contact a Lennox dealer.
D
Visually inspect for exhaust leaks (blowby). Check for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.
XP-6344 6/10
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.
Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank.
3.6.1
Checking and Filling Coolant
Maintain the coolant level in the coolant overflow bottle between the High and Low markings. See Section 1,
Service Views, for the coolant overflow bottle location.
Note: Periodically check the coolant level by removing the radiator’s pressure cap. Do not rely solely on the level in the coolant overflow bottle.
Add fresh coolant until the level is just below the overflow tube opening. Use a coolant mixture of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing.
Note: A coolant solution of 50% ethylene glycol provides freezing protection to --37
°C (--34°F) and overheating protection to 129
°C (265°F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant.
When checking the coolant level, also check the rubber seal of the radiator’s pressure cap and replace a
Section 3 Scheduled Maintenance 19
cracked or deteriorated cap. The pressure cap raises the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with the same rating type of cap. Find the pressure cap rating in Figure 3-5. Remove dirt and other debris from the pressure cap and filler neck.
Item
Pressure cap
Thermostat
Rating
97 kPa (14 psi)
91
_C (195_F)
Figure 3-5 Pressure Cap and Thermostat Rating
To prevent generator shutdown or damage because of overheating, keep the cooling air inlets clean and unobstructed at all times. Inspect the radiator’s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins. Check the hoses and connections for leaks and replace any cracked, frayed, or spongy hoses.
3.6.2
Draining Cooling System
The radiator contains a coolant drain valve to drain the cooling system. When draining the coolant, remove the radiator’s pressure cap, which will allow the entire system to drain and will prevent air pockets from forming and restricting coolant passage to the block.
Note: Pay special attention to the coolant level. After the coolant drains, allow time for complete refill of the engine water jacket. Check the coolant level as described earlier.
3.6.3
Filling Cooling System
1. Close the radiator’s coolant drain valve and tighten the hose clamps.
Note: Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack.
Wait until engine has cooled.
2. Fill the radiator with the recommended coolant mixture of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing.
The coolant capacity is shown in
Figure 3-6.
Model
RGEN30
Coolant Capacity, L (gal.)
11.5 L (3.0 gal.)
Figure 3-6 Coolant Capacity
3. Operate the engine with the radiator cap removed until the thermostat opens and the upper radiator hose becomes hot.
4. Stop the engine and allow it to cool.
5. Add coolant to the radiator to just below the overflow tube on the filler neck. See Section 1,
Service Views, for the overflow tube location.
6. Replace the radiator’s pressure cap.
7. Maintain the coolant level in the coolant overflow bottle between the High and Low markings. See
Section 1, Service Views, for the coolant overflow bottle location.
Note: Periodically check the coolant level by removing the radiator’s pressure cap. Do not rely solely on the level in the coolant overflow bottle. Add fresh coolant until the level is just below the overflow tube opening.
3.6.4
Flushing and Cleaning
For optimum protection, drain, flush, and refill the cooling system at the interval listed in the service schedule.
Flushing and Cleaning Procedure
1. Remove the pressure cap and open the radiator’s coolant drain valve and let the system drain completely. Remove the pressure cap to simplify draining.
2. Drain, clean, and flush the coolant overflow bottle.
3. Flush the system with clean water.
4. Close the radiator’s coolant drain valve.
5. Fill the system with the recommended coolant.
6. Replace the pressure cap.
3.6.5
Pressure Cap
The cooling system utilizes a pressure cap to raise the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with a cap of the same rating. Find the pressure cap rating in Figure 3-5.
20 Section 3 Scheduled Maintenance XP-6344 6/10
3.7 Battery
Consult the battery manufacturer’s instructions regarding battery care and maintenance.
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup.
Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases.
Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire.
To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
3.8 Ignition System
Service the spark plugs at the interval specified in the service schedule using the following procedure.
Spark Plug Service Procedure
1. Place the generator set master switch in the OFF position.
2. Disconnect the power to the battery charger, if equipped.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling. Do not pull the wire. Pulling on the wire rather than the boot may damage the wire or terminal.
5. Loosen the spark plug with a ratchet and 5/8-in.
spark plug socket with a rubber insert to prevent spark plug damage.
6. Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber.
7. Remove spark plugs, one at a time, and examine.
Identify a normal spark plug in good operating condition by observing a light tan or gray deposit on firing tip.
See Figure 3-7 to evaluate engine condition by color/condition of a problem spark plug.
8. Clean spark plugs by wiping them with a rag. File the center electrode to keep it parallel to the side electrode.
Note: Do not sandblast, wire brush, scrape, or otherwise service spark plug in poor condition.
Obtain a new plug for best results.
XP-6344 6/10 Section 3 Scheduled Maintenance 21
Problem/Condition
Gap-bridged spark plug
Oil-fouled spark plug
Carbon-fouled spark plug
Means of Identification
Built-up deposits and gap between electrodes closing.
Wet, black deposits on the insulator shell, bore, and electrodes.
Black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes.
Lead-fouled spark plug Dark gray, black, yellow, or tan deposits; or a glazed coating on the insulator tip.
Pre-ignition damaged spark plug
Melted electrodes and possibly blistered insulator. Metallic deposits on insulator suggest internal engine damage.
Overheated spark plug White or light gray insulator with small black or gray/brown spots with bluish (burned) appearance on electrodes.
Worn spark plug Severely eroded or worn electrodes.
Possible Cause/Solution
Oil or carbon fouling. Clean and regap the spark plug.
Excessive oil entering combustion chamber through worn rings and pistons, excessive clearance between valve guides and stems, or worn or loose bearings. Replace the spark plug.
Incorrect spark plug, weak ignition, clogged air intake, overrich fuel mixture, or excessive no-load operation. Clean and regap the spark plug.
Caused by highly leaded fuel. Replace the spark plug.
Wrong type of fuel, incorrect timing or advance, too hot a plug, burned valves, or engine overheating. Replace the spark plug.
Engine overheating, wrong type of fuel, loose spark plugs, too hot a plug, low fuel pressure or incorrect ignition timing. Replace the spark plug.
Caused by normal wear and failure to replace spark plug at prescribed interval. Replace the spark plug.
Figure 3-7 Engine Evaluation Using Spark Plug Condition
9. Check the spark plug gap before installing any spark plug. See Figure 3-8. Attain a correct gap when the feeler (or wire) passes between the spark plug electrode. It should pass easily but with some resistance or drag; otherwise adjust as necessary.
The correct gap is 0.8-0.9 mm (0.031-0.035 in.).
10. Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap. See Figure 3-9.
Position the side electrode directly over the center electrode.
1
2
1. 0.8-0.9 mm (0.031-0.035 in.) gap
2. Spark plug electrodes
Figure 3-8 Spark Plug Gap Inspection
1-514
Figure 3-9 Spark Plug Gap Adjustment
1-511
22 Section 3 Scheduled Maintenance XP-6344 6/10
11. Reinstall the spark plug.
Do not bump the electrode against the cylinder head. Rotate the spark plug clockwise until you feel resistance.
12. Use a torque wrench to torque each spark plug to
25 Nm (18 ft. lbs.). Otherwise, hand-tighten the spark plug until you feel resistance.
13. Use a ratchet wrench to final tighten an additional
1/4 turn. Do not overtighten, as doing so may strip the threads or alter the electrode gap setting.
14. Check the spark plug wire connector in the boot for accumulated dirt, grease, and other debris, and clean as necessary.
15. Firmly push the spark plug boot onto the spark plug.
16. Check that the generator set master switch is in the
OFF position.
17. Reconnect the generator set engine starting battery, negative (--) lead last.
18. Reconnect the power to the battery charger, if equipped.
3.9 Belt Check
Check the belt tension at the intervals specified in the service schedule.
If the tension is not within specification, adjust as necessary using the following procedure. See Figure 3-10.
Adjust the tension of the alternator/fan belt so that the belt can be depressed about 7 -- 10 mm (0.3 -- 0.4 in.) when applying finger pressure.
Use the following procedure to adjust the belt.
2
1
4
3
1. Battery charging alternator pulley
2. Adjusting screw
3. Check the alternator belt tension here
4. Alternator pivot screw
Figure 3-10 Belt Tension
Belt Tensioning Procedure
1. Disconnect the battery, negative lead first.
2. Loosen the pivot and adjusting screws.
3. While prying the battery charging alternator outward, tighten the adjusting screw.
4. Tighten the pivot screw.
5. Recheck and adjust as necessary.
6. Reconnect the battery, negative lead last.
Note: Also check the fan belt for cracks or tears and replace the belt if necessary.
XP-6344 6/10 Section 3 Scheduled Maintenance 23
3.10 Storage Procedure
Follow the procedure below when storing your generator set for a long period (3 months or more).
1. Start and run the generator set until it reaches operating temperature or about 15 minutes.
2. Stop the generator set.
3. Change the oil and oil filter; see Section 3.3.5, Oil and Filter Change.
4. Drain the fuel completely from the fuel tank to prevent accumulated moisture from mixing with the fuel.
5. Check the engine coolant protection; see
Section 3.6.
Note: Use antifreeze capable of withstanding the lowest possible temperatures.
6. Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs.
7. Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion.
8. Seal the air inlet, exhaust pipe, and fuel tank cap with tape.
9. Disconnect and remove the battery.
Place the battery in a warm, dry location for the storage period.
Recharge the battery once a month to maintain a full charge.
10. Select a well-ventilated (not humid or dusty) location to store the generator.
11. Cover the entire unit with a dust cover.
Note: Run the generator set once a month whenever possible.
24 Section 3 Scheduled Maintenance XP-6344 6/10
4.1 Introduction
Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker.
The charts include a list of common problems, possible causes of the problem, and recommended corrective actions.
If the procedures in this manual do not explain how to correct the problem, contact a Lennox dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to equipment.
4.2 Fault Codes
The controller displays fault codes to aid in troubleshooting.
Fault codes, descriptions, and recommended checks are listed in Figure 2-4.
Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Section 2.4.5.
4.3 Circuit Protection
If the generator set circuit breaker trips or the fuses blow repeatedly, contact a Lennox dealer for service.
4.3.1
Line Circuit Breaker
A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. The line circuit breaker location is shown in Figure 1-2. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position.
4.3.2
Fuses
Three 10-amp fuses are located on the junction box near the circuit breaker panel. Four additional engine fuses are located inside the engine fuse box. See the service views in Section 1 for the fuse locations and
Figure 4-1 for replacement fuse part numbers.
Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to Figure 4-2,
Troubleshooting Chart, for conditions that may indicate a blown fuse. Obtain service from a Lennox dealer.
Section 4 Troubleshooting
F1 Auxiliary Winding Fuse. A replaceable 10-amp fuse protects the alternator.
F2 Relay Fuse. A replaceable 10-amp fuse protects the engine relays. If the generator set does not crank, check the battery and battery connections and then check the relay fuse.
F3 Controller Fuse.
A replaceable 10-amp fuse protects the controller circuitry. If the controller display is dark, check the battery and battery connections and then check the controller fuse.
Engine Fuses. Four engine fuses are located in the engine fuse box.
Contact a Lennox dealer for replacement fuses.
Fuse Description
F1
F2
F3
10 Amp Auxiliary Winding
10 Amp Relay Interface Board
10 Amp Controller
Figure 4-1 Fuses
Part Number
358337
223316
223316
XP-6344 6/10 Section 4 Troubleshooting 25
4.4 Generator Set Troubleshooting
Figure 4-2 contains generator set troubleshooting, diagnostic, and repair information.
Check for loose connections before replacing parts.
Problem
The generator set does not crank.
The generator set cranks but does not start, starts hard, lacks power, or operates erratically.
Possible Cause
Battery weak or dead.
Battery connections reversed or poor.
Controller fuse (F3) blown.
Relay interface board fuse (F2) blown.
Engine fuse blown.
Generator set master switch in the OFF position.
Air cleaner clogged.
Battery weak or dead.
Battery connection poor.
Spark plug wire connection loose.
Low oil pressure shutdown.
Fuel pressure insufficient.
Engine fuse blown.
Controller fuse (F3) blown.
Engine fuse blown.
Auxiliary winding fuse (F1) blown.
Corrective Action
Recharge or replace the battery.
Check the connections.
Replace the fuse. Contact a Lennox dealer for service if fuse blows repeatedly.
Move the master switch to the RUN position.
Clean and/or replace the air cleaner.
Recharge or replace the battery.
Clean and tighten the battery connections.
Check the spark plug wires.
Check the oil level.
Check the fuel supply and valves.
Replace the fuse. If the fuse blows again, contact a
Lennox dealer.
Engine malfunction.
Contact a Lennox dealer.
No AC output.
AC circuit breaker in the OFF position.
Place the circuit breaker in the ON position.
AC circuit breaker tripping because of overload. Reduce the load on the generator set.
AC circuit breaker tripping because of short circuit.
Contact a Lennox dealer for service.
Auxiliary winding fuse (F1) blown.
Engine fuse blown.
Generator set overloaded.
Replace the fuse. Contact a Lennox dealer for service if fuse blows repeatedly.
Reduce the load.
Low output or excessive drop in voltage.
Generator set stops suddenly.
Low oil pressure shutdown.
Out of fuel.
Overcrank shutdown.
Check the oil level. Check for oil leaks.
Check fuel supply.
Reset the controller. If the overcrank fault occurs again, contact a Lennox dealer.
Replace the fuse. If the fuse blows again, contact a
Lennox dealer.
Replace the fuse. Contact a Lennox dealer for service if fuse blows repeatedly.
Overspeed shutdown.
Reset the controller. If the overspeed fault occurs again, contact a Lennox dealer.
Move the switch to the correct position (RUN or AUTO).
Generator set master switch in the OFF/RESET position.
Remote stop command received from a remote switch, remote digital gauge, or ATS.
Engine malfunction.
Check the remote switch position.
Contact a Lennox dealer.
Figure 4-2 General Troubleshooting Chart
26 Section 4 Troubleshooting XP-6344 6/10
4.5 Controller Troubleshooting
Figure 4-3 contains troubleshooting information for the controller.
Problem
Controller LED display is off.
Possible Cause
Controller may power down if the generator set has not run for 48 hours or longer, depending on the controller’s Cn setting. See
Section 2.4.6, Controller Power Down.
Controller fuse (F3) is blown.
Corrective Action
Controller display will automatically activate when a remote start command is received or the generator set master switch is moved to the RUN position.
Low or no battery voltage.
Generator set master switch is in the
OFF/RESET position.
Figure 4-3 Controller Troubleshooting Chart
Replace the fuse. See Figure 4-1. If the fuse blows again, contact a Lennox dealer.
Check connections.
Check generator set battery. See Figure 4-2.
Move generator set master switch to the AUTO or
RUN position.
XP-6344 6/10 Section 4 Troubleshooting 27
Notes
28 Section 4 Troubleshooting XP-6344 6/10
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